Construction of buildings



- Omit. Z2, 1929.

' tH. J. 'SCHUBERT CONSTRUCTION 0F BUILDINGS Filed April zo, 1928 2Sheets-Sheet l ATTORN EY Oct. 22, 1929. H. .1. SCHUBERT coNsTRUcTI'oN oFBUILDINGS Filed April 20. 192B 2 Shana-Sheet 2 l gh ATTORNEY PatentedGet. 22, 1929 UNTED STATES PATENT OFFICE HERMANN J. SCHUBERT, OF

CONSTRUCTION Application tiled April 20,

This invention relates to the construction of the walls and other partsof buildings, and has for some of its objects, simplicity, cheapness,durability, and strength.

Facing sheets or material consisting of cast slabs or tiles previouslymanufactured are used on the outside of my improved constructiomin frontand rear, and between them a binding and filling concrete or similarmixture is laid, in connection with which suitable air spaces areprovided through the utilization of hollow sections of ordinarycorrugated board of paper or similar substance, or other cellular sheetsor units, folded or shaped as desired, which can permanently remain inthe structure after the stitlening forms are removed, and thus insurecontinuous air Spaces of excellent and peculiar form to guard againstheat and cold and dampness at all seasons of the year; though in someforms of the invention the air ducts are omitted. g

In carrying out the method of wall construction now proposed, I suggestnumerous novel and elfective procedures, not only in the provision ofcertain kinds of precoustructed material, but in the character of thestruct-ural units, and the interposition of contrasting materials, andthe insertion of temporary and removable forms, so that a wall or otherformation may be built of any desired size, using any composition withsuch proportions of cement and crushed stones or gravel as may beneeded, with all thicknesses and air spaces, as required and demanded inall cases; and with such alternating, overlap, or stagger forms as mayhelp to strengthen by a novel interlock, to permit continuous filling.In these Various and similar ways, the wall may be built quickly andcheaply, with results superior in many respects. And the inven tionfurther consists, with these manifold objects, essentially in theconstruction, com bination and arrangement of parts, contributed by thenecessary working steps, substantially as will be hereinafter describedand claimed.

In the annexed drawings illustrating my invention HAoKEnsacK, NEW JERSEYor BUILDINGS 1928. Serial N0. 271,560.

Figure l is a horizontal sectional plan of my improved buildingconstruction.

Figure 2 is a vertical cross-`section of the same on the line 2, 2, ofFigure l. i

Figure 3 is a vertical longitudinal section n of the same on the line 3,3, of Figure l, the same being on a smaller scale.

Figure 4 is a cross-section on the line 4, 4, of Figure l.

Figure 5 is a side elevation of one of the B0 concrete slabs or tiles.

Figure 6 is a perspective view of one of the corrugated hollow air ductmembers.

Figure 7 is avertical section of a modified form of the invention,showing its applica- 6l tion to a wooden clapboard structure of house.

Similar characters of reference designate corresponding part-sthroughout all the different figures of the drawing.

The blocks, tiles, slabs, or sheets 1 are cast or molded in any desiredmanner, from any species of concrete or other suitable composition,employing ingredients that are proper to create these artificial stoneunits that are 751` capable of being successfully used to veneer oroverlay the outer and inner face, or otherwise, of a building Wall. Iclaim a Wide latitude of shape and materials for their manufacture; andthey are provided as completed blocks ready for use in my improvedbuilding construction. One of these slabs l is shown in detail in Figure5. Its outer face is preferably smooth, and its inner face is formedwith integral ribs 2 produced there- 85- on simultaneously With thecastingof the wall slab, for the purpose of strengthening the wall andenabling the inner and outer walls to be more effectively united by theinner filling of mortar or other substance. On one longitudinal edge isa tongue 4, and on one transverse edge is a tongue 4", while on theother edges are grooves, as 1l and 4C. 1When a plurality of these slabsare supported on each other the tongues and grooves interlock on alledges with the corresponding tongues and grooves of adjoining slabs,fitting neatly together Without mortar. Further it will be noted thatWhile the slabs are being molded in the molds and before being set,dried or baked, transverse passages'are formed in the ribs 2 closeagainst the wall of slab l, by placing rods or implements in the moldsin the soft material to form passages 3, and withdrawing the rods afterthe setting of the material, whichpassages 3 will receive the angularends 56L of bent rods or struts 5 which I use to hold'the outer andinner slabs l of a wall properly distanced or in a spaced relation apartwhile therwall is being built, all as clearly indicated in Figure 2.

As I have already suggested, in building the wall of a house, a numberof the sla-bs l will be set up on edge, with their ribs 2 on the inside,and their ends and edges interlocking, as many of these slabs being usedas may be needed for the outside area of the Y outer` wall to be built;and opposite this outer Wall, similar slabs l will be set up to form theinner wall, to be properly spaced from the outer wall, all as shown inFigure 2. Struts or rods 5 having right-angled ends 5la will be placedin a horizontal position between the walls at suitable intervals, withthe ends agengagingthe holes 3 in opposite ribs 2. See Figure 2. Withthe outer and inner walls thus started to be erected, and occupyingvertical positions, the space between them willjbe filled with a softconcrete, composite mortar, or filling of some kind. I will now explainhow this isdone.

I find it convenient to make air duets in sectional form andV to moldthese into the yfilling within the wall where they will remainpermanently after the wooden forms on which they yare shaped and heldwhile the filling is being poured in around them have been removed.Thematerial of these air ducts is somewhat light and fairly stiff paperor` papier mache board or the like, vas the Y common and well knowncorrugated board,

which consists of parallel. paper sheets a and b ywith an intermediatecorrugated paper layer @,all three parts glued or cemented together into-a vunitary combination. See Figure 6. Thus the paper board itselfprovides further air channels in its 'own constitution. Any othercellular board might serve a similar purpose and I wish to broadly claimthese air cells, tubes, or channels arranged throughout the mass of thewall to give the valuable advantages accruing from such a provision.

,This corrugated board, or its equivalent, is shaped insections v6 ofrectangular form and of convenient length for handling, and are madewith anV extension single leaf 7 on one side. `The length of section 6is about the same as the width of slab l so that when the erection ofthe wall is started and slabs l are setup vertically opposite eachother, a row of the'sections 6 can be set up centrally within the. spacebetween the slabs, as shown in Figure 2. Sections 6 correspond in shapeVto the wooden forms 8 which are rectangular pieces of plank or boardthat are placed within the sections 6 before the latter are placed inposition, with the upper ends of the forms 8 projecting above sections6, these upper ends being perforated at 9 or otherwise shaped so thatthey can be grasped with a hook or tool to remove the forms 8 after thcsections 6 are set in mortar or filling 10.

In Figure l a row of the paper board sections 6 is shown in positionbetween slabs l. The leaf 7 reaches from one section 6 to the nextsection and slightly overlaps the edge of it. The strut 5 which connectsopposite slabs l between the ends of two sections 6 passes through theleaf 7 at this point. A hole can be easily punched through leaf 7 topermit this. After a row of sections 6 has been located in place invertical upright position the mortar or filling l0 is poured in to fillthe space between slabs l and around the sections 6 and between the endsthereof, and around leaves 7. When this is all com plete and the fillinghas hardened more or less, the board forms 8 can be withdrawn, leavingthe hollow sections 6 of said row rigidly in position. The next upperrow of sections 6 with their inserted forms 8 will next be provided andplaced in similar position as the members of the previous row but on topof same, and in an alternate position with respect to their le aves 7which are new on the opposite side instead of directly above the leaves7 below, said leaves 7 being therefore in planes parallel to each other,but projeeting in opposite directions in the different rows, as themembers rise in a vertical series piled one on the other. l This isclearly shown in Figure l and Figure 2. In order to more surely centerone section 6 directly above the section 6 under it I allow the form 8in the upper section to project slightly below the lower end of saidsection so that it may enter the upper open end of said lower sectionand hold the two sections in accurate alignment until the mortar has setsu'liiciently around the upper section to maintain it in position.llVhen therefore the second row of sections 6 has been thus superposedon the first the filling l0 will be poured in to lill the space asbefore, and after it is hardened the forms 8 will be withdrawn and a newrow of sections brought forward to make the third series. And so on, thewall may be built up as high as desired, first placing the outer slabsin position, then the inner corrugated board members, and then admittingthe plastic filling.

The mounting of sections 6 on each other in a vertical series providesan air duct or channel of any desired length, which is most beneficialin the wall construction, for it affords continuous air spaces to keepout heat and cold and dampness and other deleterious influences.

I have spoken of how the different rows of sections 6 have their leaves7 projecting in opposite directions in the different rows, so that theyoccupy two vertical parallel planes instead of the leaves 7 all being inthe same vertical plane. This alternating or stagger arrangement causesthe leaf on one section to lie on one side in one plane and the leaf onthe next section above or below it to lie on the other side in anothervertical plane, instead of both leaves being directly in line with eachother. This is accurately brought out in Figure 2. This arrangement ofleaves permits the concrete or lling l() to flow in a solid mass betweenand around the leaves, thus creating a continuous mass throughout thespace between slabs or blocks l, which would not be the case if theleaves were all in a vertical row, for they would then form a partitionthat would divide the filling into two parts, and it would not be nearlyso strong or homogeneous, but with the alternating or oppositely-placedleaves the distribution is perfect and equal in all parts.

It will be understood that the corrugated paper board members 6 form apart of the material brought together to form the wall. These members,as it were, are open-end cartons in rectangular form, made by anysuitable machinery that will cut and shape the board to form a ductsection, as 6, with its edge stapled, riveted, or otherwise securedafter the folding is complete, and leaving the Aintegral leaf projectingat one side of about the size of the larger face ofthe section. Thesesections 6, so made and shaped, may without injury thereto, be iatteneddown into a thin, flat, sheet, for purposes of shipment, and will thusoccupy only a very small space. When taken for use they are quicklyopened or distended into theirnormal rectangular form, where theyreceive the closely tting wooden forms 8 that keep them stiff and rigidwhile the composition of stone and cement is drying and hardening aroundthe duct sections in the wall interior.

While the invention is primarily intended for the construction of awall, and to this end combines the prepared slabs, the prepared airchannels, and the binder that unites them all in a solid mass, yet thereare many cases where it is desirable to face the outside of a woodenbuilding, like a clapboarded house, with a covering of the slabs 1 togive it the appearance of smooth or rough stucco, and not onlyrejuvenate its appearance, but give it a longer lease of life byimparting strength and tightness, as well as warmth and dryness thereto;and sometimes a newly build wooden house can be similarly iinished toadvantage.

This construction presents certain modications of my invention, and Ihave illustrated the same in Figure 7 by showing a vertical section ofsuch a wall, whose exterior overlaid with slabs l. Here l5 denotes anupright joist or timber belonging to the building frame, on the insideof which are' the laths 14 and plaster 13, while on the outside are theboards to which are nailed the overlapping clapboards 16. The slabs l1,equivalent to slab l, is supported outside the boards 16 by means ofheaded pins l2 that are driven into the woodwork, and have their angularends l2a engage recesses l1a in the inner ribs on slabs l1. Further theslabs 11 will have tongues 11b and grooves 11.

Thus far I have described my improved wall as containing the air ducts.There are many cases however where the air passages may be omitted. Thisis particularly so in the foundation wall of a building. In making suchfoundation I still use the slabs or tiles l, placing them one uponanother as before, and holding them in position by the struts or rods 5,so that they are spaced apart to allow the fluid mortar or compositionto be poured into the space. When this hardens I have a solid wall, asbefore, but without the air spaces, as they are not needed in thefoundation wall. There are moreover other places where a solid wall likethis is desirable. Therefore my invention broadly covers a wall with theduplex parts held together by struts and filled with composition,whether or not the channels are provided.

What I claim, is: j

l. In the construction of buildings, the combination with outer andinner walls of superposed interlocking slabs having inner ribs castintegral therewith, of means. for spacing these walls and holding themin such spaced relation, continuous air passages consisting of hollowsections of paper board, each section having a leaf, and said sectionsbeing mounted one upon another, with their leaves in different rowsprojecting in opposite planes, and a binding composition lling the spacebetween the walls and around between the air sections and the leavesthereof, to create a hard and substantial mass.

2. In the construction of buildings, the combination with outer andinner walls of superposed interengaging slabs, of air passagesconsisting of superposed hollow sections, each having a leaf, the leafon the sections of one horizontal row extending on opposite sides so asto lie in a pair of vertical planes instead of a single plane, and abinding material filling the space within the walls and around the airpassages and between the leaves of the latter so as to unite all thesemembers in a solid mass.

3. In the construction of buildings, the combination with outer andinner walls composed of a plurality of members supported one uponanother in a vertical series, each member having perforated inner ribs,of hooked rods engaging the perforated ribs to hold the outer and innerwalls in spaced relation to each other and sectional air ducts eachcomposed of sections placed one on another in a vertical series and heldin place by said spaces for the filling, which is used to ill allfilling, board.

said sections being made ot paper the wall space around the airchannels.

In testimony whereof I hereunto aiiix my 4. In building construction,the combinasignature.

tion with walls spaced apart and composed of interlocking slabs ortiles, rods arranged between the walls tor holding them in spacedrelation to each other, a iilling between them consisting ot a concretevcomposition poured in in a fluid condition and allowed to set, and aseriesV of air ducts composed of sections ot corrugated board that areset in the illing, said sections. having wings that occupy a staggerrelation to each other.

5. In the construction of buildings of the class described, thecombination with inner and outervwalls ot superposed interlockingprepared cast slabs, ot pre-constructed air duct sections that areassembled in continuous series in the space between the walls. saidsections being formed ot corrugated paper board in rectangular form, oneedge being secured to the body ot the section. and the section beingadapted to be collapsed tlatwise for shipment, and distended into hollowshape fori use and to contain a removable vstiii'ener while the sectionis being set, together with a ,composite filling in the space in thewalls and between the air ducts that will harden in a solid mass.

6. In the construction ot buildings ot the class described, thecombination with inner and outer walls ot' cast pre-constructed slabs ortiles having inter-engaging tongues and grooves, of prepared sections otair ducts that areassembled in continuous series in the space betweenthe walls, said sections being placed in horizontal rows, said sectionsbeing formed .40. of paper board bent into rectangular form,

one edge being secured to the'body of the section, and each sectionhaving a single leaf, each alternate section in every horizontal row otsections having its leat on the opposite side ot the section, so that avertical series ot sections will have alternate gaps to allow acontinuous space around the leaves, and a soft concrete filling in allthe spaces within the walls. v

7. In the construction ot building walls, the combination of inner andouter walls composed of a plurality ot interlocking units, means holdingthese walls a distance apart, air channels madeup ot leaf-providedsections, one horizontal row ot which have their leaves projectinghorizontally from one section to the nextl in the row and adjoining theouter wall, and the next horizontal row ot sections having their leavesprojecting horizontally from one section to the next in the row andadjoining the inner wall, and the other rows ot sections all havingtheir leaves. similarly alternately staggered, so that the leaves lie intwo vertical parallel planes, to provide continuousF HERMANN J.SCHUBERT.

